Complementary mating elements for double-skin foam core panel

ABSTRACT

A double-skin building construction panel having a foam core and having an outer facing sheet laterally offset from and spaced apart from an inner facing sheet. Each panel presents an overlapping edge portion along one side and an overlapped edge portion along its opposite side. The panels are adapted to be assembled in lapped relation without externally visible fasteners. Mating elements in the outer facing sheets provide a positive mechanical connection of adjacent outer facing sheets and provide for lateral adjustment in the position each panel relative to the previously erected panel. The arrangement is such that during erection, the panels may be gathered or spread apart to conform the coverage provided by all of the panels with that required by the structural framework.

[ Dec. 11, 1973 United States Patent 1 Tischuk COMPLEMENTARY MATINGELEMENTS FOR DOUBLE-SKIN FOAM CORE PANEL Primary Examiner-Price C. Faw,Jr.

Attorney-Harry B. Keck et al.

[75] Inventor: Walter Tischuk, Richmond, Ind.

H. H. Robertson Company, Pittsburgh, Pa.

[57] ABSTRACT A double-skin building construction panel having a [73]Assignee:

[22] Filed. Aug. 30, 1972 foam core and having an outer facing sheetlaterally offset from and spaced apart from an inner facing PP N04285,060 sheet. Each panel presents an overlapping edge portion along oneside and an overlapped edge portion along its opposite side. The panelsare adapted to be [52] US. 52/309, 52/483, 52/595 [51] Int.

assembled in lapped relation without externally visible E04c 1/10, E04c2/20 fasteners. Mating elements in the outer facing sheets [58] Field ofSearch...................... 52/235, 309, 595,

provide a positive mechanical connection of adjacent outer facing sheetsand provide for lateral adjustment in the position each panel relativeto the previously [56] References Cited UNITED STATES PATENTS erectedpanel. The arrangement is such that during erection, the panels may begathered or spread apart to conform the coverage provided by all of thepanels Glards 52695 with that required by the structural framework.Tischuk 52/595 6 Claims, 11 Drawing Figures 5040 47.48 r y r 0257 97363333 PATENTED BEE 1 I 1975 SHEEF 2 OF 3 FIG FIG.7

PATENIED DEC 1 I 1973 SHEET 3 BF 3 COMPLEMENTARY MATING ELEMENTS FORDOUBLE-SKIN FOAM CORE PANEL BACKGROUND OF THE INVENTION 1. Field of theInvention This invention relates to double-skin foam core buildingconstruction panels of the type erected without externally visiblefasteners, and more particularly to improvements in complementary matingelements formed in at least the outer facing sheets of such buildingconstruction panels.

2. Description of the Prior Art Double-skin building construction panelshaving no lateral adjustment capability and which are erected withoutexternally visible fasteners are known in the prior art for use in theconstruction of buildings, see U.S. Pat. Nos. 3,290,845 (SNYDER, Dec.13, 1966), 3,535,844 (GLAROS, Oct. 27, 1970); 3,667,180 (TIS- CHUK, June6, 1972). Double-skin building construction panels having some lateraladjustment capability and which are erected without externally visiblefasteners also are known in the prior art, see U.S. Pat. No. 3,372,520(HENSEL, Mar. 12, 1968).

The SNYDER, GLAROS and TISCHUK panels require extensive field cuttingand fitting to conform the lateral coverage of the panels with thatdictated by the structural-framework. The HENSEL arrangement requiresthe use of specially shaped, slotted and apertured subgirts incombination with a special clamping plate and fastener to achieveerection and lateral adjustment of the panels. Moreover, the erectionand lateral adjustment require the cooperative effort of workmenpositioned exteriorly and interiorly of the building framework.

SUMMARY OF THE INVENTION The principal object of this invention is toprovide an improved laterally adjustable weather-tight joint betweendouble-skin foam core building construction panels.

Another object of this invention is to provide improved complementarymating elements for at least the outer facing sheet of a double-skinfoam core building construction panel, which mating elements permit thepanels to be gathered or spread apart thereby to conform the lateralcoverage of the panels with that required by the structural framework.

Still another object of this invention is to provide improvedcomplementary mating elements which permit lateral adjustment of theposition of each panel relative to a previously erected panel withoutimpairing the weather seal.

The present invention provides improvements in the building constructionpanel described and illustrated in U.S. Pat. No. 3,667,l80, supra. Inthe building construction panel of U.S. Pat. No. 3,667,180, supra, eachof the facing sheets includes a central web, first and second side wallsextending along the opposite side edges of the central web and a flangeextending outwardly from the second side wall generally parallel to thecentral web. The facing sheets are assembled such that the flange ofeach facing sheet confronts the opposing central web of the other facingsheet and is laterally spaced-apart from the first side wall of theother facing sheet.

In accordance with the present invention, connecting means formed in thefirst and second side walls of the outer facing sheet provide a positivemechanical connection between the outer facing sheets of adjacentpanels. The connecting means, in the form of a recess and acomplementary tongue, are arranged such that the position of each panelrelative to the previously erected panel may be adjusted laterally,whereby the lateral coverage provided by all of the panels is conformedwith that required by the lateral dimensions of the building structuralframework.

The recess is formed integrally with the second side wall of the outerfacing sheet and is spaced-apart from both the central web and theflange. The recess, having a generally U-shaped configuration, presentsconfronting first and second interior wall segments extending generallyparallel with the central web, and a connecting wall segment. Thecomplementary tongue is formed integrally with the first side wall ofthe outer facing sheet and extends outwardly therefrom into the recessof the adjacent facing sheet. The complementary tongue comprises a firstexterior wall segment which is generally parallel with the firstinterior wall segment of the recess. A second exterior wall segmentadjoins the first exterior wall segment to provide a leading edge remotefrom the first side wall. Preferably, the second exterior wall segmentof the tongue forms an acute angle with the first exterior wall segment.A sealant in the fOlIl'l of a bead of caulking material or a sealantstrip formed from a soft, closed cell plastic or sponge rubber, isintroduced into the recess at a location wherein the sealant ispenetrated by the leading edge of the adjacent facing sheet to provide aweather-tight seal.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a fragmentary elevation viewof the present building wall panels erected on a building structuralframework;

FIG. 2 is a cross-sectional view taken along the line 22 of FIG. 1,illustrating the transverse profile of the present building constructionpanel;

FIG. 3 is an exploded, isometric view of clip and fastener means;

FIG. 4 is a fragmentary cross-sectional view taken along the line 4-4 ofFIG. 1;

FIG. 5 is an end view illustrating the profile of the facing sheets usedin the building panel of FIG. 2;

FIG. 6 is a fragmentary cross-sectional view, taken along the line 6--6of FIG. 1, illustrating the normal joint spacing between adjacentpanels;

FIGS. 7 and 8 are fragmentary cross-sectional views, similar to FIG. 6,illustrating the minimum and maximum joint spacing between adjacentbuilding panels;

FIG. 9 is a fragmentary cross-sectional view taken along the line 99 ofFIG. 1;

FIG. 10 is an isometric view illustrating an alternative sealant strip;and

FIG. 11 is a fragmentary cross-sectional view similar to the right handhalf of FIG. 6, illustrating the sealant strip of FIG. 10 installed inthe present panel.

DESCRIPTION OF THE PREFERRED EMBODIMENT FIG. 1 illustrates a buildingstructural framework 10 of which only vertically spaced horizontalsub-girts 11 and two laterally spaced vertical columns 12a, 12b areillustrated. The building structural framework 10 supports a wallstructure 13. The wall structure 13 is assembled from plural buildingpanels 14 erected in edge overlapped relation and presenting pluraljoints 15. Each of the panels 14 is secured to selected ones of thesubgirts 11 by clip and fastener means 16.

Each of the panels 14 (FIG. 2) comprises an outer facing sheet 17, aninner facing sheet 18 and a plastic foam core 19 disposed between thefacing sheets 17, 18. Each of the facing sheets 17, 18 includes acentral web 20 having first and second side walls 21, 22 provided alongthe opposite longitudinal edges thereof. A flange 23 extends outwardlyfrom the second side wall and is generally parallel with the central web20.

The facing sheets 17, 18 are laterally offset from one another, overallarrangement being such that the flange 23 of each facing sheet 17(18)confronts the opposing central web 20 of the other facing sheet 18(17)and is laterally spaced-apart from the first side wall 21 of the otherfacing sheet 18(17). The panel 14 presents an overlapping edge portion24 and an overlapped edge portion 25. A gap 26 is presented at each ofthe edge portions 24, 25 between the flange 23 and the adjacent firstside wall 21. The foam core 19 is exposed at the gaps 26.

The fastening means 16 (FIG. 3) comprises a clip member 27 and afastener 28. The clip member 27 includes a first arm 29 provided withcentral and end apertures 30 and a second arm 31. The clip member 27preferably is in the form of an angle wherein the first and second arms29, 31 are mutually perpendicular. The fastener 28 preferably is of theself-tapping type.

When the clip 17 is installed (FIGS. 4 and the first arm 29 overlies theflange 23 of the outer facing sheet 17 and the second arm 31 extendsinto the foam core 19 in the region (gap 28) between the flange 32 ofthe outer facing sheet 17 and the first side wall 21 of the inner facingsheet 18. The fastener 28, when installed, extends through one of theopenings 30 in the first arm 29, the foam core 19, the inner facingsheet 18 into the sub-girt 11. It will be appreciated that the clipmember 17 and the fastener 28 cooperate to provide a positive connectionbetween the outer facing sheet 17 and the inner facing sheet 18, and topositively secure the inner facing sheet 18 to the sub-girt 11. For amore complete description of the fastening means 16, reference is madeto U.S. Pat. No. 3,667,180, supra.

Referring to FIG. 5, each of the facing sheets 17 (18) presents a recess32 and a complementary tongue 33. The recess 32 is formed in the secondside wall 22 and is spaced-apart from both the central web and theflange 23. The recess 32 has a generally U-shaped configurationincluding confronting first and second interior wall segments 34, 35which extend generally parallel with the central web 20, and aconnecting wall segment 36.

The complementary tongue 33 is formed in the first side wall 21 andcomprises first and second exterior wall segments 37, 38. The firstexterior wall segment 37 adjoins the first side wall 21 and extendsoutwardly therefrom generally parallel with the central web 20. Thesecond exterior wall segment 38 adjoins the first exterior wall segment37 to provide a leading edge 39 remote from the first wall segment 21.The second exterior wall segment 38 extends away from the central web 20and forms an acute angle indicated at 40, with the first exterior wallsegment 37.

It will be observed in FIG. 5 that the recess 32 has an interior heightindicated at 41 and that the tongue 33 has an exterior thicknessindicated at 42. Also, the hidden face 45 of the first exterior wallsegment 34 of the recess 32 is spaced from the exterior web face 47 at adistance indicated at 43; and that the exposed face 46 of the firstexterior wall segment 37 of the tongue 33 is spaced from the exteriorweb face 47 at a distance indicated at 44. In accordance with thepresent invention and depending upon the gauge of metal used in formingthe facing sheet 17, 18, the interior height 41 of the recess 32 exceedsthe thickness 42 of the tongue 33 by 2 to 4 metal thicknesses; and thedistance 44 exceeds the distance 43 by l to 2 metal thicknesses. Theoverall arrangement is such that when adjacent panels 14A, 14B (FIG. 6)are assembled to form the joint 15, the tongue 33 of the panel 14B iscentered with respect to the recess 32 of the adjacent panel 14A. Notealso that the exposed tongue face 46 is spaced apart from the hiddenrecess face 45.

Further in accordance with this invention, a bead 56 of sealant material(FIG. 5) is applied across substantially the entire width and along theentire length of the hidden face 45 of the recess 32.

FIG. 6 illustrates the normal installed position of the adjacent panels14A, 14B. It will be observed that a space 50 normal joint spacing ispresented at the joint 15. However, the dimensions 48 and 49 (FIG. 5)are such that the normal joint spacing 50 can be adjusted between twoextremes, that is, wherein no space minimum joint spacing 55 (FIG. 8) ispresented at the joint 15; and wherein a maximum joint spacing 51 (FIG.7) is presented at the joint 15. Thus in accordance with this invention,the position of each panel may be adjusted laterally with respect tothat of the previously erected panel prior to securing each panel to thesubgirts 11. For example, in the joint formed between panels of onecommercial embodiment, the normal joint spacing is three-thirtysecondthinch; the maximum permissible joint spacing is three-sixteenth inch; andthe permissible variation in the joint space from three-thirtysecondthinch is plus or minus threethirtysecondth inch.

It will also be appreciated that since the fastening means 16 (FIG. 6)is installed from the exterior of the building framework, the entirewall structure 13 (FIG. 1) can be erected by workmen positioned solelyat the exterior of the building framework.

The importance of the position and extent of the sealant bead 56 (FIG.5) within the recess 32 will now become apparent from the following. Afragment of a panel 14C is illustrated in dotted outline at the righthand side of FIG. 6. It will be observed that as the tongue 33 of thepanel 14C enters the recess 32 of the previously erected panel 148, theleading edge 39 is positioned to engage the sealant bead 56. When thetongue 33 reaches its final position, as shown at the left hand side ofFIG. 6, a portion of the sealant head 56 has been displaced from itsinitial position. However, since the exposed tongue face 46 isspaced-apart from the hidden recess face 45, a portion of the sealanthead 56 remains between the exposed tongue face 46 and the hidden recessface 45. The same is true for the panels at the maximum joint spacing 51(FIG. 7) and for the minimum joint spacing 55 (FIG. 8). Accordingly,regardless of the joint spacing, a weather-tight seal is provided.

Returning to FIG. 1, it will be observed that corner panels 14a, 14b areapplied to the vertical columns 12a, 12b. The construction and installedposition of a typical corner panel is illustrated in FIG. 9. The cornerpanel 14a (14b) has no exposed trim elements and provides anaesthetically pleasing, visual continuity in the appearance of thepanels along adjacent building faces. The panel 14a may comprise one ofthe panels 14 which is bent along its longitudinal center line of thefacing sheet 17.

Referring again to FIG. 1, each of the panels 14 has a modular widthindicated at M, which corresponds to the distance between the first andsecond side walls 21, 22 (FIG. 5). Prior to erecting the panels 14, theoverall distance indicated at D in FIG. 1, between the corner panels 14aand 14b is determined. If the position of the vertical columns 12a, 12bis in accordance with the engineering drawings, then the panels 14 canbe erected at the normal joint spacing 50 (FIG. 6). However, if thedistance between the vertical columns 12a, 12b is ei ther less than orgreater than that specified, the difference will be reflected in theoverall distance D.

The joint spacing is determined by subtracting from the overall distanceD, the product of the number of panels times the modular coverage M. Theremainder is then divided by the number ofjoints. Erection of the panels14 to the desired joint spacing may be accomplished by the aid of gauges52 of which only one is illustrated in FIGS. 6 and 7. The gauge 52 has agauging end 53 adapted to be inserted between the adjacent panels 14a,14b and a handle 54. The gauging end 53 may, for example, be providedwith one or more strips 55 of predetermined thickness to arrive at thedesired joint spacing.

FIG. illustrates an alternative sealant strip 57 formed from softpolyvinyl chloride or soft silicone rubber preferably of the closed celltype. One face of the sealant strip 57 is provided with an adhesivecoating 58 which is protected by a stripable backing sheet 59. Thesealant strip 57 is installed in the recess 32 of the panel 14D (FIG.11). When installed, the sealant strip 57 is secured by the adhesivecoating 58 (FIG. 10) to the connecting wall segment 36. The sealantstrip 57 also engages the interior face 45 of the first interior wallsegment 34 and is thus positioned for engagement by the tongue 33 of theadjacent panel 14E thereby to provide a weather-tight seal.

I claim:

1. In a wall structure assembled from plural building panels spanningacross plural spaced-apart sub-girts of a structural framework anderected in side-by-side overlapped relation; each of said panels havingan outer facing sheet laterally offset from and spacedapart from aninner facing sheet, and a foam core disposed therebetween; each of saidfacing sheets including a central web, first and second side wallsextending along the opposite sides of said central web, and a flangeextending outwardly from the second side wallgenerally parallel to saidcentral web, the flange of each facing sheet confronting the opposingcentral web of the other facing sheet and being laterally spaced-apartfrom the first side wall of the other facing sheet; said panels beingerected (a) with the first side wall of each facing sheet confrontingthe second side wall of the adjacent facing sheet, and (b) with saidflange of each outer facing sheet positioned inboard of and spacedapartfrom said flange of each said inner facing sheet; and clip and fastenermeans engageable with the flanges of the outer facing sheets forsecuring said panels to certain of said sub-girts; the improvement inlaterally adjustable connecting means providing a positive mechanicalconnection between the outer facing sheets of adjacent panels,comprising:

said second side wall of each outer facing sheet having a recess formedintegrally therein and sacedapart from said central web and from saidflange. said recess comprising confronting first and second interiorwall segments extending generally parallel with said central web, and aconnecting wall segment; and a complementary tongue formed integrallywith said first side wall of each outer facing sheet and extendingoutwardly therefrom into the recess of the adjacent facing sheet, saidcomplementary tongue comprising a first exterior wall segmentconfronting said first interior wall segment and being generallyparallel therewith, and a second exterior wall segment adjoining saidfirst exterior wall segment to provide a leading edge remote from saidfirst side wall; the width of said complementary tongue and the depth ofsaid recess being such that prior to securing said panels to saidsubgirts, the position of each panel may be adjusted laterally withrespect to the previously erected panel, thereby to conform the lateralcoverage provided by all of said panels with that required by saidstructural framework. 2. The improvement of claim 1 including a sealantmaterial applied to the first interior wall segment of said recess, saidsealant material being penetrated by said leading edge of the adjacentfacing sheet to provide a weathertight seal. 3. The improvement of claim2 wherein said second exterior wall segment forms an acute angle withsaid first exterior wall segment. 4. The improvement of claim 2 whereinthe first interior wall segment of said recess is positioned adjacent tosaid central web. 5. The improvement of claim 1 wherein the spacingbetween the first and second side walls of form throughout said wallstructure.

6. The improvement of claim 1 wherein said second and first side wallsof each said inner facing sheet are provided with a said recess and asaid complementary tongue, whereby laterally adjustable positivemechanical connections also are provided between the inner facing sheetsof adjacent panels.

the outer facing sheets of adjacent panels is uni-

1. In a wall structure assembled from plural building panels spanningacross plural spaced-apart sub-girts of a structural framework anderected in side-by-side overlapped relation; each of said panels havingan outer facing sheet laterally offset from and spaced-apart from aninner facing sheet, and a foam core disposed therebetween; each of saidfacing sheets including a central web, first and second side wallsextending along the opposite sides of said central web, and a flangeextending outwardly from the second side wall generally parallel to saidcentral web, the flange of each facing sheet confronting the opposingcentral web of the other facing sheet and being laterally spaced-apartfrom the first side wall of the other facing sheet; said panels beingerected (a) with the first side wall of each facing sheet confrontingthe second side wall of the adjacent facing sheet, and (b) with saidflange of each outer facing sheet positioned inboard of and spaced-apartfrom said flange of each said inner facing sheet; and clip and fastenermeans engageable with the flanges of the outer facing sheets forsecuring said panels to certain of said sub-girts; the improvement inlaterally adjustable connecting means providing a positive mechanicalconnection between the outer facing sheets of adjacent panels,comprising: said second side wall of each outer facing sheet having arecess formed integrally therein and saced-apart from said central weband from said flange, said recess comprising confronting first andsecond interior wall segments extending generally parallel with saidcentral web, and a connecting wall segment; and a complementary tongueformed integrally with said first side wall of each outer facing sheetand extending outwardly therefrom into the recess of the adjacent facingsheet, said complementary tongue comprising a first exterior wallsegment confronting said first interior wall segment and being generallyparallel therewith, and a second exterior wall segment adjoining saidfirst exterior wall segment to provide a leading edge remote from saidfirst side wall; the width of said complementary tongue and the depth ofsaid recess being such that prior to securing said panels to saidsubgirts, the position of each panel may be adjusted laterally withrespect to the previously erected panel, thereby to conform the lateralcoverage provided by all of said panels with that required by saidstructural framework.
 2. The improvement of claim 1 including a sealantmaterial applied to the first interior wall segment of said recess, saidsealant material being penetrated by said leading edge of the adjacentfacing sheet to prOvide a weathertight seal.
 3. The improvement of claim2 wherein said second exterior wall segment forms an acute angle withsaid first exterior wall segment.
 4. The improvement of claim 2 whereinthe first interior wall segment of said recess is positioned adjacent tosaid central web.
 5. The improvement of claim 1 wherein the spacingbetween the first and second side walls of the outer facing sheets ofadjacent panels is uniform throughout said wall structure.
 6. Theimprovement of claim 1 wherein said second and first side walls of eachsaid inner facing sheet are provided with a said recess and a saidcomplementary tongue, whereby laterally adjustable positive mechanicalconnections also are provided between the inner facing sheets ofadjacent panels.